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Image-based finite element modelling of fibre dynamics in polyester staple spun yarns
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Researchers built a detailed computer model of how individual fibers move and stress inside a polyester yarn, using X-ray imaging to capture the yarn's actual 3D structure. Beyond improving textile engineering, this model offers a new tool for understanding how microplastic fibers break off from fabrics during everyday use.
This paper introduces an innovative finite element (FE) modelling approach for fibre dynamics in a staple spun yarn based on the geometrical model derived from X-ray microcomputed tomography (μCT) images. The FE model retains crucial in situ information on fibre anisotropy, length, and continuity while employing advanced stitched scanning technique to reconstruct a 15mm yarn length containing individual fibres with ∼10μm diameter. The research focuses on 100% polyethylene terephthalate (PET) staple ring-spun yarn as a case study, conducting both single fibre and yarn tensile tests to characterise material properties and validate the FE model, respectively. Beyond examining the mechanical response at the yarn level, the model facilitates the investigation of individual fibre’s tensile stress, frictional forces, and extent of migration, thereby enhancing the understanding of fibre interactions during yarn tensile loading. Furthermore, the model enables parametric studies through manipulation of inter-fibre friction coefficients allowing assessment of their impact on overall mechanical behaviour. This innovative modelling approach demonstrates significant potential for exploring the constitutive and failure mechanisms for formation of microplastics from textiles and textile materials in general as well as fibre-reinforced composites. It addresses the critical research gaps in simulating anisotropic behaviours of materials containing textile fibres, paving the way for advanced material design and analysis in materials science and engineering. • μCT-based model simulates fibre dynamics in staple spun yarn using FE methods. • 15mm yarn model closely aligns with experimental tensile test results. • Fibre position and migration significantly influence stress evolution in yarn. • Friction coefficient variation affects mechanical response, especially at low values. • Model aids in understanding microplastic formation and fibre composites mechanism.
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